Utility standard repair devices and methods

ABSTRACT

A square riser with corner threaded rods is used to repair utility standards. The riser threaded rods are bolts with washers welded to the bolt heads. The utility standard base is removed from its footing with four threaded rods, the riser slid down over the footing threaded rods and welded to them. Nuts on the footing threaded rods are used to level the riser. The riser can if desired be filled with poured concrete, to strengthen and protect it. The utility standard base is then slid down over the riser threaded rods and secured by nuts. A sleeve made of two paired half shells snugly fitting the bottom of the utility standard above the base can be welded to the utility standard. Reinforcing brackets are sometimes welded to the middles of the half shells and to the standard base. On occasion both methods of repair may be combined. It is far cheaper to repair than replace utility standards. The methods and material meet all North American standards for utility standard repair.

[0001] The invention relates to devices and methods to repair, reinforce damaged utility standards, including light, communication, power and traffic standards, which are expensive to replace, cost ranging from $900 to $1500 Canadian funds, plus an average of $700 Canadian funds installation costs (2002).

[0002] In areas where temperatures fall below freezing, utility standards, including lamp posts, and communication, power, and telegraph standards and the like made of metal, typically steel, corrode at the bottom typically due to water and salt being splashed on to the metal standard. Similarly where there is regular flooding corrosion occurs. The bottom portion of the standard is in practice the most likely to corrode and need repair, reinforcement. Such repair is considerably cheaper than removing and replacing the standard.

BACKGROUND

[0003] Generally modern utility standards comprise a hollow metal standard standing on a footing, typically of concrete. The standard typically has a standard square base flange with corner holes to receive threaded rods or bolts set into the footing. Nuts secure the base to the threaded rods, studs or bolts.

[0004] The invention includes a riser, this is a squarish metal riser with four metal sides, with bolts or threaded rods welded at the top corners. The standard is unbolted and temporarily removed. The existing footing threaded rods are then cut down. The riser is set slid down over the cut down rods, and welded to them. The riser can if desired be filled with concrete, to strengthen and protect it. The standard is then set on the riser threaded rods and bolted in place. Usually this procedure is applied to lift the base out of very wet situations. The invention includes a reinforcing metal half shell, which is specifically shaped to fit the standard exterior snugly, so two half shells fit together around the standard. The shells are held in place by a chain or the like wrapped around the standard, then spot or tack welded to each other and the standard then circumferentially welded top and bottom and butt welded at the joins. The two half shells cover and reinforce the damaged bottom portion of the standard.

[0005] Although the invention is described and referred to specifically as it relates to specific devices, structures and methods for repair, reinforcement of utility standards by risers and half shells, it will be understood that the principles of this invention are equally applicable to similar devices, structures and methods for repair, reinforcement of such standards, it will be understood that the invention is not limited to such devices, structures and methods for repair and reinforcement of such standards.

PRIOR ART

[0006] The prior art of which applicant is aware is hereby made of record. U.S. Pat. Nos. 1,799,319, to Kjekstad, Jan. 29, 1929, 3,755,977, to Lewis, Oct. 29, 1971, 3,796,957, to Dougherty, Mar. 12, 1974, 3,870,350, to Loncaric, Mar. 11, 1975, 4,097,165, to Quayle, Jun. 27, 1978, 4,175,311 to Bunyan, Nov. 27, 1979, 4,333,218 to Wentworth, Jun. 8, 1982, 4,747,430 to Stata et al., May 31, 1988, 4,799,340 to Lichau et al., Jan. 24, 1989, 4,986,687 to Ivey, Jan. 22, 1991, 5,337,469 to Richey, Aug. 16, 1994, 5,573,354 to Koch, Nov. 12, 1996, 6,038,823 to Gallimore et al., Mar. 21, 2001, all teach repairs to pipes, posts, standards and the like.

DESCRIPTION OF THE INVENTION

[0007] In a first broad aspect of the invention is directed to a riser for a utility standard. Utility standards have a footing with four upright threaded rods forming a horizontal square. The riser comprises a square base comprising four sides joined at four corners, and is sized so as to fit outside and touch the footing threaded rods. Typically each riser side is a substantially rectangular metal plate having top, bottom and side edges. Each plate is joined at each side edge at right angles to another plate's side edge. Conveniently the riser has upright threaded rods attached at each upper corner and aligned with the corners of its base. These threaded rods may be welded in place at the standard site. Generally the plates are welded to each other at the side edges, and the threaded rods are bolts welded to the base corners. More preferably each riser bolt has a washer threaded thereon, and tack welded to the head of each bolt. Threaded rods in this connection are often called studs. The bases of the utility standards are generally square with apertures for threaded rods, studs or bolts at the corners.

[0008] In another broad aspect the invention is directed to a method of repairing and elevating a utility standard comprising the step of fitting a riser comprising a square base comprising four sides joined at four corners, over the footing for the utility standard. The footing has four upright threaded rods forming a horizontal square. The riser base is sized so as to touch the footing threaded rods adjacent the inner corners of the riser. Preferably the footing threaded rods are welded to the riser. More preferably nuts are threaded down the footing threaded rods to the footing, the riser is fitted over the footing threaded rods to rest on the nuts, which are then adjusted in height to level the riser, and the riser is welded to the footing threaded rods and their nuts. If desired concrete is poured to fill the riser, to protect and strengthen it. Preferably the top part of the footing threaded rod are cut off, before fitting the riser over the footing threaded rods. Generally the riser has upright threaded rods attached at each upper corner and aligned with its corners. Preferably these upright threaded rods are welded to the upper corners of the riser. More preferably the heads of upright bolts are welded to the upper corners of the riser. More preferably washers are threaded on each bolt and tack welded to the head of each bolt. The base of the utility standard, which has apertures for footing threaded rods can be slid over the riser threaded rods. The utility standard base is then secured to the riser threaded rods by nuts.

[0009] In a further broad aspect the invention is directed to a repaired utility standard comprising a footing having four upright threaded rods forming a horizontal square. A riser is fitted over the footing. The riser has a square base comprising four sides joined at four corners, and sized so as to fit outside and touch the footing threaded rods, which are welded to the riser. The riser has riser upright threaded rods attached at each upper corner and aligned with the corners of the riser base. A utility standard has a base having therein four apertures spaced apart to receive the footing threaded rods. The riser threaded rods pass through the utility base apertures. Nuts engage the riser threaded rods and secure the utility standard in position. Preferably the riser threaded rods are upright bolts welded to the riser corners. More preferably each riser bolt has a washer threaded thereon, and tack welded to the head of each bolt. Preferably footing nuts are threaded onto the footing threaded rods, and the riser rests on the footing nuts and is welded to the footing nuts and the footing threaded rods. If desired the riser base is filled with poured concrete, to protect and strengthen it.

[0010] In another broad aspect the invention is directed to a half shell of a repair sleeve for a metal utility standard. The half shell is sheet metal with top, side and bottom edges, with an exterior surface and an interior surface. The interior surface conforms snugly to half of the perimeter of the bottom of the utility standard. Preferably the half shell has a tack welding aperture adjacent the middle of the half shell. Adjacent the middle means as close to this point as feasible or convenient. Often the half shell is tapered upward to conform to a tapered utility standard. This is more advantageous the further the half shell extends up the standard. The half shell may be semicylindrical to fit a cylindrical standard. The half shell may be semipolygonal to fit a polygonal standard. Polygonal standards have equal sides and may be triangular, square, pentagonal, hexagonal, octagonal, decagonal and dodecagonal, and in theory there is no restriction to the number of sides. In practice triangular is known but rare, square, hexagonal and octagonal are common. The half shell may consist of a number of regular polygonal facets. Or and this is sometimes more convenient since the side edges meet on a regular facet of the polygonal standard, the half shell has regular polygonal facets with side half regular polygonal facets.

[0011] In a further broad aspect the invention is directed to a method of repairing a utility standard, which comprises welding to the utility standard against the bottom thereof, two half shells of sheet metal having top, side and bottom edges, an exterior surface and an interior surface. Each interior surface conforms snugly to half of the perimeter of the bottom of the utility standard. Preferably when the standard has a projecting base, and is very bad state the additional step is taken of butt welding brackets vertically up the middle of each half shell, and horizontally outward on the base. Preferably initially a first bottom circumferential bead is welded around the bottom of the utility standard abutting its base. Then the half shells are placed with their bottom edges abutting the bottom circumferential bead, and tightened in place, by an encircling cable, chain or wire. The half shells are then spot welded to each other and the standard, while tightened in place. Preferably the half shells are spot welded to each other and the standard at the top corners, bottom corners, and about the midpoints of the side edges, and to the standard itself at the midpoints of top and bottom edges. At this point the cable, chain or wire is no longer necessary and is removed. Then a top circumferential bead is welded along the top edges of the half shells, and a further bottom circumferential bead is welded along the bottom edges of the half shells. This further bottom circumferential bead, usually overlaps the first bottom circumferential bead. Often the further bottom circumferential bead, welded in this step, comprises two, rarely more, overlapping beads, in addition to the original bead. Next butt beads are welded along the side edges of the half shells. Generally this is done after the top and bottom circumferential beads, but sometimes before. When the half shells have tack welding apertures adjacent the middle thereof, the half shells are tack welded to the standard through these apertures. This is done before the spot welding step to additionally secure the half shells to the standard, then the process of spot welding, circumferential bead welding and butt bead welding is carried out as indicated. Whether or not the half shells are tack welded to the standard through the tack welding apertures, a final optional step may include the step of placing brackets vertically up the middle of the half shells and horizontally outward horizontally outward on the standard base and welding butt beads between brackets and half shells and between brackets and base.

[0012] In a last broad aspect the invention is directed to a repaired utility standard, which has a footing and a base integral with the standard. The standard has welded thereto above and abutting the base two half shells of sheet metal having top, side and bottom edges, an exterior surface and an interior surface. Each interior surface conforms snugly to half of the perimeter of the bottom of the utility standard. Preferably the half shells are welded to the standard by a top circumferential bead along the top edges of the half shells, and by a bottom circumferential bead along the bottom edge of the half shells, and butt welds along and joining the side edges of the half shells. When the half shells have tack welding apertures in the middle thereof, the tack welding apertures are tack welded to the standard. The standard may have brackets welded vertically up the middle of the half shells and welded horizontally outward to the standard base, preferably the brackets are butt welded to the half shells and base. Sometimes the repaired utility standard of has a footing having four upright threaded rods forming a horizontal square. A riser is fitted over the footing. The riser has a square base comprising four sides joined at four corners, and is sized so as to fit outside and touch the footing threaded rods, which are welded to the riser. The riser has riser upright threaded rods attached at each upper corner and aligned with the corners of the riser base. The utility standard has a base having therein four apertures spaced apart to receive the footing threaded rods. Instead the riser threaded rods pass through the utility base apertures, while nuts engage the riser threaded rods and secure the utility standard in position. Preferably the riser threaded rods are upright bolts welded to the corners, and each riser bolt has a washer threaded thereon, and tack welded to its head. Preferably footing nuts are threaded onto the footing threaded rods, the riser rests level on the footing and is welded to the footing nuts, and threaded rods. Optionally the riser base is filled with poured concrete, to protect and strengthen it.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013]FIG. 1 shows a riser of the invention.

[0014]FIG. 2 shows a riser of the invention in use.

[0015] FIGS. 3 to 9 show half shells of sleeves of the invention.

[0016] FIGS. 10 to 14 show stages of a repair procedure using half shells of the invention.

[0017]FIG. 15 shows a repaired standard embodying riser and sleeve.

[0018]FIGS. 16 and 17 show a concrete protected riser of the invention in plan and sectional elevation.

[0019]FIGS. 18 and 19 show a side reinforced repaired standard of FIG. 15 in elevation and top sectional plan.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0020] The invention is now illustrated by reference to preferred embodiments thereof. FIG. 1 shows riser 10 being lowered onto utility standard concrete footing 12, with the standard removed, which has below grade portion 14 shown in ghost, and above grade portion 16 which is typically square in cross section with level square top 18, at the corners of which are threaded rods 20, 22, 24 and 26. These threaded rods (also called studs), are typically about 2 inch high and 1 inch in diameter, although other dimensions are sometimes met. They are typically spaced some 6 or 6½ (newer) or 7 inches (older) apart in a square. In installation these are cut off to about ½ inch high, and nuts 27 threaded onto each stud down to footing top 18. Riser 10 is then lowered until it rests so the cut off studs abut the bottom inner corners of riser 10, which rest on nuts 27. Riser 10 is then levelled by adjusting the height of nuts 27 on studs 20, 22, 24 and 26. Riser 10 is then tack welded to nuts 27 and studs 20, 22, 24 and 26, usually at its inner corners, sometimes against its inner sides. Riser 10 has four metal plates 28, 30, 32, 34, typically steel, usually mild steel, which are joined at their ends to form corners, typically by welding. On the top corners are welded vertically threaded rods, 36, 38, 40, 42, also called studs, which as shown are hex bolts. The metal plates are typically ¼ inch thick sheet metal, although as thin as {fraction (1/16)} inch to as thick as desired could be used, and are 3 to 6 inches high and 6 to 12 inches wide, in practice most are 3 inches high and 7¼ inches wide external, ¾ inches internal. In practice suitable sizes and thicknesses can routinely be determined by those skilled in the art. If a different size riser is needed sufficient risers are made for the purpose in hand. Studs 36, 38, 40 and 42, are typically 3 inch galvanized bolts, with 1 inch diameter. Generally riser 10 has studs 36, 38, 40 and 42 welded on before being taken to the repair site. Sometimes studs 36, 38, 40 and 42 are welded to riser 10 at the site. The ¼ inch thickness of plates 28, 30, 32 and 34, allows some variation in placement of studs 20, 22, 24 and 26 at the corners. Washers 45, 1 inch in internal diameter and ¼ inch thick are tack welded to studs 36, 38, 40 and 42. After the riser is welded in place, optionally interior 44 of riser 10 can be filled with concrete. Outer circular frame 120 (two part not shown) which touches riser 10 at the corners and is the same height, is placed around riser 10 and both are filled with concrete 122 inside 122 outside (FIGS. 16 and 17). After concrete 122 has set frame 120 is removed, the concrete strengthens protects installed riser 10 from rusting. Riser 10 is usually concrete protected, but not always. The standard is then lowered onto riser 10, its base apertures sliding down over studs 36, 38, 40 and 42, and nuts tightened down on studs 36, 38, 40 and 42. The older standard bases have 1⅜ inch bolt apertures centred about 7 inches apart, which allows some leeway in positioning studs 36, 38, 40 and 42 on riser 10. FIG. 2 shows a standard repaired by riser 10. Standard base 46 supporting standard 54 is held on riser 10 by four nuts, three of which, 48, 50 and 52 are shown. Riser 10 can in theory be as small as 1 inch square. The most likely reason for using riser 10 to raise standard base 46 is that the base may sit in water in summer, or be flooded regularly causing the base to corrode, it may also be subject to road salt build up in winter again causing it to corrode. By raising the base of the utility standard we can prolong standard life substantially. Another reason for raising the base of the utility standard is when streets are resurfaced above their current existing grade, thus allowing lifting the utility standard the same distance.

[0021] FIGS. 3 to 9 show sleeves 58 of paired half shells 60 of the invention. Utility standards are generally tapered metal tubes of about 11 gauge, about ⅛ inch thick, metal, which is typically steel, stainless steel, or aluminum. Fiberglass and concrete standards are also available. Half shells of the invention are sized so as to fit snugly over the outside bottom portion of the utility standard. Typically but not always the corroded portion of the standard is restricted to the bottom 8 inches of the standard. Generally utility standards have an access or inspection panel near the base, which often protrudes from the side of the standard. Sleeve 58, so half shells 60, must fit below any such protrusion. In FIGS. 3 to 9 are shown sleeves 58 of common half shell pairs 60. FIG. 3 shows hexagonal half shells 62, 64, each with two hexagonal facets 66 and two half hexagonal facets 68, two preferred tack welding apertures 70, one in each half shell 62, 64, are shown in a middle facet. FIG. 4 shows another hexagonal half shell pair 72, 74, each with three hexagonal facets 66, again preferred tack welding aperture 70 is shown in the middle facet. FIG. 5 shows semicylindrical half shell pair 76, 78, each with a preferred middle tack welding aperture 70 shown. FIG. 6 shows square half shell pair 80, 82, each with one square facet 84 and two half square facets 86, with preferred tack welding aperture 70 shown in the middle of square facet 86. FIG. 7 shows another square half shell pair 88, 90, each with two square facets 84, with preferred tack welding aperture 70 shown in facet 84. FIG. 8 shows a octagonal half shell pair 92, 94 each with three octagonal facets 96 and two half octagonal facets 98, with preferred tack welding aperture 70 shown in the middle octagonal facets. FIG. 9 shows another octagonal half shell pair 100, 102 each with four octagonal facets 96 and two half octagonal facets 98, with preferred tack welding aperture 70 shown in middle octagonal facets. The half shells are generally from 6 to 24 inches tall, preferably 11 gauge, ⅛ inch steel, preferably galvanized. Their width is sized to fit the standard bottom, in theory this can be as small as 1 inch square, and their thickness as little as {fraction (1/16)} inch. In practice suitable sizes and thicknesses can routinely be determined by those skilled in the art. The procedure for installation of half shell pairs 60 starts with inspection of the corroded portion of the standard. When corrosion has damaged the standard bottom, it is inspected to see if there is sufficient material for sleeve attachment. If so it is then checked for encrusted rust and the like. Generally this is removed by using a cutting torch to burn rust, other debris and troublesome paint off. A suitable sleeve is selected and then checked for fit. Sometimes the sleeve makes a good fit, sometimes adjustment is needed carried out by hammering the sleeve to change existing bends. The nuts securing the standard base to its footing are then checked to see if they obstruct making a weld at the standard base join, if so they are removed one at a time as the welding pass is made. FIG. 10 shows a damaged standard 54 with corrosion hole 104 secured at base 46 by nuts 48, 50, 52, to footing 12. Circumferential bead weld 106 is then made near the standard base join, if the standard is polygonal, the bead weld will also be polygonal. FIG. 11 shows half shells 76, 78, which are then placed against standard 54 with their bottoms against circular weld 106. In practice any type of half shell 60 may be used, but for purpose of illustration semicylindrical half shells are shown. FIG. 12 shows chain or cable 108 passed around half shells 76, 78, and tautened to hold then in position. When a chain is used a bolt is passed through two links and secured by a nut, and the chain tightened by inserting and levering a prybar. At this point when the tack welding apertures are present, tack welds 110 are made through these to hold the two half shells against the standard. FIG. 13 show half shells 76, 78 are then strategically welded to the standard by spot welds 112, the same procedure is followed when the tack welding apertures are absent. Typically the half shells are spot welded at their top and bottom corners to the standard and each other, at the middle of their join, and at the middle of the top and bottom of half shells, 76, 78, if desired more spot welds may be made. FIG. 14 shows chain 108 and prybar are removed, and half shells 76, 78 welded to standard 54 by top circumferential weld bead 114, and by bottom circumferential bead 116, which is often multiple, sometimes two or three superposed beads times at the bottom, often over earlier circumferential bead 106, then butt welded at the join by butt welds 118. The sleeve is then primed and painted. FIG. 15 shows a repaired utility standard incorporating both riser 10 and sleeve 58 of the invention. Riser 10 elevates base 46 above footing 12, while sleeve 58 incorporating half shells 76, 78 is secured to standard 54 by tack welds 110, circumferential welds 114 and 116, and butt weld 118. Sometimes the bottom of standard 54 is very badly corroded. As shown in FIGS. 18 and 19 reinforcing side brackets, wedges or triangles 130 and 132 are butt welded by welds 134 and 138 to half shells 76 and 78 respectively, and by butt welds 136 and 140 to base 46. Wedges 130 and 132 are typically ¼ inch steel, and the same height as half shells 76 and 87, typically 6 inches. Generally the wedges are placed at right angles to the half shell middles, and 90° around the standard from the half shell join, in most of the standard bases there is from 1 to 1¼ inches free space between half shells 76 and 78 and the edge of base 46. The wedges are typically 6 inches tall, ¼ inch thick and project 1 to 1¼ inches from the half shells. The effect of wedges 130 and 132 is to buttress the bottom of standard 154 and reduce movement during wind.

[0022] The welding rod used is {fraction (5/32)} inch structural elongation welding rod 7018, which is a low hydrogen welding rod. The welds stretch but do not break, which is advantageous when welding utility standards the tops of which move in the wind, thus stressing the welds at the bottom of the standard. Low hydrogen is preferred because it avoids or reduces embrittlement due to the presence of hydrogen. Other welding rods of closely similar properties can be utilized instead as would be appreciated by those skilled in the art.

[0023] Throughout the welding process, paint at the welding site is scored and removed to provide clean welding surfaces as would be understood by those skilled in the art.

[0024] The methods and material meet all North American standards for utility standard repair.

[0025] As those skilled in the art would realize these preferred described details and materials and components can be subjected to substantial variation, modification, change, alteration, and substitution without affecting or modifying the function of the described embodiments.

[0026] Although embodiments of the invention have been described above, it is not limited thereto, and it will be apparent to persons skilled in the art that numerous modifications and variations form part of the present invention insofar as they do not depart from the spirit, nature and scope of the claimed and described invention. 

I claim
 20. Half shell of repair sleeve for metal utility standard, comprising sheet metal having top, side and bottom edges, an exterior surface and an interior surface said interior surface conforming snugly to half of the perimeter of the bottom of said utility standard.
 21. Half shell of claim 20, wherein said half shell has a tack welding aperture adjacent the middle of said half shell.
 22. Half shell of claim 20, wherein said half shell is tapered upward to conform to a tapered utility standard.
 23. Half shell of claim 20, wherein said half shell is semicylindrical.
 24. Half shell of claim 20, wherein said half shell is semipolygonal.
 27. Method of repairing a utility standard comprising the step of welding to said utility standard against the bottom thereof, two half shells of sheet metal having top, side and bottom edges, an exterior surface and an interior surface, each said interior surface conforming snugly to half of the perimeter of the bottom of said utility standard.
 28. Method of claim 27, wherein said standard has a projecting base, comprising the additional step of butt welding brackets vertically up the middle of each half shell, and horizontally outward on said base.
 29. Method of claim 27, comprising the initial step of welding a first bottom circumferential bead around the bottom of said utility standard abutting its base.
 30. Method of claim 29, comprising the steps of placing said half shells with their bottom edges abutting said bottom circumferential bead, and tightening them in place.
 31. Method of claim 29 comprising the step of spot welding said half shells to each other and said standard, while tightened in place.
 32. Method of claim 31, comprising the steps of spot welding said half shells to each other and said standard at the top corners, bottom corners, and about the midpoints of the side edges, and to said standard at the midpoints of top and bottom edges.
 33. Method of claim 32, comprising the steps of welding a top circumferential bead along the top edges of said half shells, and welding a further bottom circumferential bead along the bottom edges of said half shells.
 35. Method of claim 33, comprising the step of welding butt beads along the side edges of said half shells.
 36. Method of claim 35 comprising the step of placing brackets vertically up the middle of said half shells and horizontally outward horizontally outward on said base and welding butt beads between said brackets and said half shells and between said brackets and said base.
 44. Repaired utility standard, said standard having a footing and a base integral with said standard, said standard having welded thereto above and abutting said base two half shells of sheet metal having top, side and bottom edges, an exterior surface and an interior surface, each said interior surface conforming snugly to half of the perimeter of the bottom of said utility standard.
 45. Standard of claim 44 having brackets welded vertically up the middle of said half shells and welded horizontally outward to said base.
 46. Standard of claim 44, wherein said half shells are welded to said standard by a top circumferential bead along the top edges of said half shells, and by a bottom circumferential bead along the bottom edge of said half shells, and butt welds along and joining said side edges of said half shells.
 47. Standard of claim 46, having brackets butt welded vertically up the middle of said half shells and butt welded horizontally outward to said base.
 49. Standard of claim 44 comprising a footing having four upright threaded rods forming a horizontal square, a riser fitted over said footing, said riser comprising a square base comprising four sides joined at four corners, said riser base being sized so as to fit outside and touch said footing threaded rods, said footing threaded rods being welded to said riser, said riser having riser upright threaded rods attached at each upper corner and aligned with said corners of said riser base, said utility standard having a base having therein four apertures spaced apart to receive said footing threaded rods, said riser threaded rods passing through said utility base apertures, nuts engaging said riser threaded rods and securing said utility standard in position.
 53. Standard of claim 49, having brackets welded vertically up the middle of said half shells and welded horizontally outward to said base. 